Air filtration device

ABSTRACT

An air filtration device ( 1 ) of an air suction system of a vehicle engine includes a suction manifold ( 2 ) extending in length along a main axis (X-X). The air filtration device ( 1 ) further includes at least two tubular filters ( 3 ), a first tubular filter ( 31 ) and a second tubular filter ( 32 ) arranged in series along said main axis (X-X) inside the suction manifold ( 2 ). The air filtration device ( 1 ) further includes a support ( 4 ) supporting the tubular filters ( 3 ) in the suction manifold ( 2 ). The support ( 4 ) includes at least one connection element ( 45 ) which mechanically supports two consecutive tubular filters, connecting the filters fluidically. Furthermore, the support ( 4 ) includes a partialization device ( 41 ) to create an obstruction to the flow of clean air flowing inside the first inner cavity ( 31 ) to favor flow of air through the second tubular filter ( 32 ).

FIELD OF APPLICATION

The present invention relates to an air filtration device and an airsuction system of a vehicle engine comprising said air filtrationdevice. In addition, the present invention relates to a suction methodof filtered air of an air suction system of a vehicle engine throughsaid air filtration device.

The context which the present invention lies in is the automotivesector. In particular, the present invention refers specifically to theair which, once aspirated, enters the combustion chamber of the internalcombustion engine.

STATE OF THE ART

In the state of the art solutions of air suction systems of a vehicleengine are known of which draw in air from the external environment toconvey it to the internal combustion chamber of the relative endothermicengine.

Such systems typically comprise filtration devices suitable to filterthe dispersed particles from the air, preventing the access of unwantedmaterial inside the combustion chamber, such as dirt or dust.

In order to improve the functioning and performance of the internalcombustion engine, it is essential for such systems to allow thegreatest possible quantity of air to enter, at the same time effectivelyfiltering it.

To achieve this objective it is therefore essential that the filtrationdevice has the widest possible filtering surface and that such surfaceat the same time performs effective filtration.

To overcome this problem, in the state of the art, solutions for airfiltration devices have been developed which comprise box-shaped bodiescontaining a plurality of air filters, typically of the tubular type,suitable to operate in parallel with each other.

However, such known solutions have as their main drawback that of havinga particularly complex and above all bulky geometry.

An example of such known solutions is, for example, shown in documentnumber WO2013057549 in the name of the Applicant.

Solution According to the Invention

The need is therefore strongly felt to have an air filtration devicewhich maximizes the flow rate of effectively filtered air to the enginewhile minimizing its overall dimensions inside the vehicle, for exampleinside the engine compartment.

The purpose of the present invention is therefore to provide an airfiltration device which satisfies these requirements, overcoming thedrawbacks of the prior art mentioned above.

Such purpose is achieved by an air filtration device according to claim1, by means of an air suction system of a vehicle engine which comprisessaid air filtration device according to claim 14. In addition, suchpurpose is also achieved by the suction method of filtered air accordingto claim 15. The dependent claims show preferred embodiment variantshaving further advantageous aspects.

DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the invention will, in anycase, be evident from the description given below of its preferredembodiments, made by way of a non-limiting example with reference to theappended drawings, wherein:

-   -   FIGS. 1a 1b, and 1c shows three perspective views of an air        filtration device according to a preferred embodiment;

FIG. 2 shows a side view of the air filtration device shown in FIGS. 1a,1b and 1 c;

FIG. 3 shows a cross-section view of the filtration device according tothe cross-section plane V-V shown in FIG. 2;

FIGS. 3a and 3b are two cross-section views of the filtration devicerespectively according to the cross-section planes A-A and B-B shown inFIG. 3;

FIGS. 4a, 4b and 4c show a perspective view and two side views of somecomponents of the air filtration device shown in the previous figures;

FIG. 5 shows a cross-section view according to the cross-section planeVI-VI in FIG. 4 c;

FIG. 6 shows a side view of an air filtration device according to thepresent invention, in a further embodiment;

FIG. 7 shows a cross-section view according to the cross-section planein FIG. 6;

FIGS. 8a and 8b are a perspective view and a cross-section view of anembodiment variant of the filtration device;

FIG. 9 is a cross-section view of a further embodiment variant of thefiltration device.

DETAILED DESCRIPTION

With reference to the appended drawings, reference numeral 1 denotes anair filtration device 1 of an air suction system of a vehicle engine inits entirely.

In particular, the air filtration device 1 according to the presentinvention finds application in the automotive sector, being positionedupstream of an engine, in particular fluidically engageable to a suctionsystem duct, to allow the filtered suction of a predefined quantity ofair as far as the combustion chamber of the engine: the air filtrationdevice 1 is suitable to allow the filtered suction of a predefined airflow rate needed for the engine to function properly.

According to a preferred embodiment, the air filtration device 1 has amain direction of extension along a main axis X-X, thus identifying amain dimension compared to the others.

Preferably, as shown also in the appended drawings, according to apreferred embodiment, the main axis X-X extends in a single direction,that is along a single straight line.

According to other preferred embodiments, the main axis X-X extends inseveral directions, identifying different linear sections. In apreferred embodiment, said linear sections lie on the same plane. Inother preferred embodiments, said linear sections lie on differentplanes.

According to the present invention, the air filtration device 1comprises a suction manifold 2 extending in length along the main axisX-X between a first end and a second end. Preferably, at the first endan outlet mouth 21 is made fluidically engageable to a system suctionduct comprised in the engine air suction system. Preferably, but notnecessarily, at the second end an inlet mouth 22 facing and fluidlyconnected to the external environment is provided; in some embodiments,the inlet mouth 22 is made in the suction manifold 2 in an axialposition comprised between the first end and the second end.

According to the present invention, the suction manifold 2 is asubstantially tubular body, suitable to convey the air from theenvironment to the system suction duct. According to a preferredembodiment, at the inlet mouth 22, the suction manifold 2 comprises aconveying funnel suitable to conveying the aspirated air inside thesuction manifold 2. Preferably, at the outlet mouth 21, a suitableconnection, which is engageable to a system suction duct, is provided oris comprised.

According to a preferred embodiment at the inlet mouth 22, the suctionmanifold 2 comprises an attachment element to the vehicle and an elasticelement for decoupling the vibrations coming from the engine such as,for example, a bellows (as shown by way of example in FIGS. 8a and 8b ).

Preferably, depending on the type of main axis X-X, the suction manifold2 identifies one or more suction manifold tubular sections 200.Preferably, said suction manifold tubular sections 200 are mutuallyaligned along the main axis X-X or each extend along a respectivedifferent linear section

According to a preferred embodiment, one or more suction manifoldtubular sections 200 are made of porous material in non-woven fabriccomposed of synthetic fibres or generically in a sound-absorbentmaterial.

According to a preferred embodiment, one or more suction manifoldtubular sections 200 are made of a plastic material, which is machinableby moulding/blowing, and possibly lined internally with asound-absorbing material such as, for example, open-cell foam. The useof porous tubular sections allows the entry of air to be filtered alongthese sections also, allowing a distribution of the incoming air flowover the entire filtering surface provided by the filtration device.

According to a preferred embodiment, the tubular sections 200 couldinclude laterally placed inlet openings (that is radially with respectto the main axis X-X) with respect to the lateral surfaces of thetubular filters (as shown by way of non-limiting example in FIG. 9).

According to a preferred embodiment, the suction manifold could comprisea first inlet mouth in a distal position and/or one or more inletopenings made on a tubular section or both.

According to the present invention, the suction manifold 2 defines withits walls an air filtration chamber 20, in which the dirty air drawn infrom the environment flows towards the outlet mouth 21. In particular,air is filtered inside said air filtration chamber 20 in such a way thatclean air flows to the outlet mouth 21.

According to the present invention, in fact, the air filtration device 1comprises at least two tubular filters 3 arranged in series along saidmain axis X-X housed inside said suction manifold 2, in the filtrationchamber 20.

In particular, the two tubular filters 3 comprise a first tubular filter31 positioned proximal to the first end and proximal to the outlet mouth21 and a second tubular filter 32 positioned proximal to the second end,preferably, but not necessarily, proximal to the inlet mouth 22. Inother words, along the main axis X-X, in the filtration chamber 20, thetwo tubular filters 31, 32 are arranged in series.

According to a preferred embodiment, the air filtration device 1comprises at least an intermediate tubular filter 33 interposed betweenthe first tubular filter 31 and the second tubular filter 32.

According to a preferred embodiment, the tubular filters 31, 32, 33 havea cylindrical shape.

According to further embodiments, the tubular filters 31, 32, 33 have aconical shape.

According to the present invention, each tubular filter 31, 32, 33 iscrossable by the air from the outside to the inside, respectivelycomprising, centrally, an inner cavity defined by an inner wall: thefirst tubular filter 31 comprises a first inner cavity 310 defined by afirst inner wall 311; the second tubular filter 32 comprises a secondinner cavity 320 defined by a second inner wall 321; the intermediatetubular filter 33 comprises an intermediate inner cavity 330 defined byan intermediate inner wall 331.

According to a preferred embodiment, each tubular filter is made ofnon-woven material in fibres interwoven with each other which isproducible using melt-blown and with synthetic fibres, such aspolypropylene, or alternatively the tubular filter may be of a pleatedseptum type consisting of a non-woven fabric with cellulose fibresand/or synthetic fibres and/or glass fibres.

According to a preferred embodiment, the tubular filters 31, 32, 33 arejoined in series, but as amply described below, they filter the air byoperating in parallel.

According to the present invention, the air filtering device 1 furthercomprises support means 4 supporting the tubular filters 3 in thesuction manifold 2. In particular, the support means 4 have a dualfunction: firstly to provide a mechanical support for the tubularfilters 3 to support them to the suction manifold 2; secondly to operatewith the tubular filters 3 to make them work in such a way that the airis filtered through them in parallel.

Preferably, the support means 4 are also suitable for connecting inseries two consecutive tubular filters along the main axis X-X.

In particular, the support means 4 comprise at least one connectionelement 45 which mechanically supports two consecutive tubular filters.Preferably, the connection element 45 fluidically connects the firstinner cavity 310 with the second inner cavity 320.

For example, in the embodiment comprising at least one intermediatetubular filter 33 the support means 4 comprise a first connectionelement 45′ which mechanically and fluidically supports the intermediatetubular filter 33 with the first tubular filter 31 and a secondconnection element 45″ which mechanically and fluidically supports theintermediate tubular filter 33 with the second tubular filter 32.

According to a preferred embodiment, the connection element has specialportions (for example annular portions and/or perforated end plates)engaged to the tubular filters (in particular to the respective filtermedia) to perform the mutual engagement.

According to a preferred embodiment, moreover, the connection element 45is also suitable for connecting said different linear sections byfluidly connecting the suction manifold tubular sections 200 whichextend along different linear sections of the main axis X-X. Preferably,in fact, the connection element 45 is also suitable for connecting twosuction manifold tubular sections 200 comprising a manifold connectionwall 452. In other words, the manifold connection wall 452 in turndefines the air filtration chamber 20.

The support means 4 further comprise a partialization device 41 housedin the first inner cavity 310 suitable to create an obstacle to the flowof clean air flowing inside said first inner cavity 310 in such a way asto favour the flow of air through the second tubular filter 32 and thusthrough the second inner cavity 320.

According to a preferred embodiment, the support means 4 comprise asecond partialization device 42 housed in the second inner cavity 320 ofthe second tubular filter 32. The second partialization device 42creates an obstacle to the flow of clean air flowing inside said secondinner cavity 320 inferior to the obstacle which the first partitioningdevice 41 creates in the first inner cavity 310.

According to a preferred embodiment which also comprises theintermediate tubular filters 33, the support means comprise anintermediate partialization device 43 housed in the intermediate innercavity 330 suitable to create an obstacle to the flow of clean airflowing inside said intermediate cavity 330 in such a way as to favourthe flow of air through the second tubular filter 32 and thus throughthe second inner cavity 320.

According to the present invention, the partialization devices affectthe flow of air which flows from the outside to the inside, so thatinside the tubular filters placed in a more proximal position to theoutlet mouth 21 there is a greater obstacle compared to the tubularfilters placed in a more distal position from the outlet mouth 21 (thatis in an area preferably more proximal to the inlet mouth 22). This waythe flow of air aspirated into the suction manifold 2 is not exclusivelyconcentrated in the areas of the filtering surface adjacent to or nearthe outlet mouth 21 (that is it avoids concentrating them in theproximity of the first tubular filter 31 only). The partializationdevices are therefore suitable to encourage the suction, in parallel,through each tubular filter (that is also through the second tubularfilter 32, or also through the intermediate tubular filter 33 and thesecond tubular filter 32). In other words, the partialization devicesincrease the pressure drop of the air through the tubular filter theylie in so as to favour an inflow of air that flows in parallel with thetubular filter arranged in an adjacent geometric position.

According to a preferred embodiment, the partialization device is of thetype suitable to occupy a portion of the volume of the respectivecentral cavity.

According to a preferred embodiment, the partialization device is of thetype suitable to perform a calibrated transit of air inside it.

According to other embodiments, the partialization device combines thetwo aforementioned partialization methods, occupying a portion of thevolume of the central cavity and forcing the air to flow throughcalibrated passages.

According to a preferred embodiment, each partialization device 41, 42,43 comprises a partialization wall 411, 421, 431 which extends in lengthand occupies the respective central cavity 310, 320, 330.

In other words, the partialization wall 411, 421, 431 defines a suctionchannel 410, 420, 430 in which the clean air aspirated through therespective tubular filter 31, 32, 33, flows.

According to a preferred embodiment, the partialization wall 411, 421,431 comprises an inlet portion 411′, 421′, 431′ which engages therespective inner wall 311, 321, 331 and an outlet portion 411″, 421″,431″ distal from the respective inner wall 311, 321, 331.

According to a preferred embodiment, the partialization wall 411, 421,431 comprises an inlet portion 411′, 421′, 431′ which mechanically andfluidically engages the adjacent connection element so as to connect thetubular filter which said partialization wall 411, 421, 431 is installedin and the tubular filter adjacent to it.

Preferably, the partialization device 41, 43 comprises centrally anoutlet passage 416, 436.

Said outlet passage 416, 436 is separated from the suction channel 410,430 by the partialization wall 411, 421, 431.

According to a preferred embodiment, in said outlet passage 416, 436 theclean air filtered by the adjacent tubular filter 32, 33 flows towardsthe outlet.

In other words, in the inner cavity 310, 330, and in particular in theoutlet passage 416, 436 defined by the respective partialization device41, 43, the air filtered by the adjacent tubular filter 330, 320 flows.

In a preferred embodiment, the suction channel 410, 420, 430 issubstantially tubular, facing the respective inner wall 311, 321, 331.

According to a preferred embodiment, the suction channel 410, 420, 430is substantially conical with a through cross-section which increasesalong the respective inner wall towards the outlet mouth.

According to a preferred embodiment, said conical geometry of thesuction channel 410, 420, 430 is obtained with a cylindrical tubularfilter and a conical partialization wall (flared towards the inletmouth) or with a tubular filter of a conical shape and a cylindricalpartialization wall.

According to a preferred embodiment, the partialization device 41, 43comprises a partialization element 415, 435.

Preferably, the partialization element 415, 435 is positioned in theinner cavity 310, 330 in a position proximal to the outlet of therespective inner cavity 310, 330.

According to a preferred embodiment, the partialization element 415, 435has a main extension substantially planar in a direction perpendicularto the main axis X-X.

According to a preferred embodiment, the partialization element 415, 435has calibrated air passages.

In other words, the partialization element 415, 435 forces the aspiratedair to flow through specific calibrated air passages, obstructing theflow.

According to the present invention, the partialization element 415, 435is housed in the suction channel 410, 430 in its outlet portion 411″,421″, 431″, having a substantially annular shape.

According to a preferred embodiment, the partialization element 415, 435is of the type comprising a porous body, for example made of fibrousmaterial.

According to a further preferred embodiment, the partialization element415, 435 is of the type comprising a perforated planar body.

According to a further preferred embodiment, the partialization element415, 435 is of the type comprising a perforated body with a mechanicallyadjustable or electrically controlled through section. In other words, athrough section and therefore a desired resistance is definedmechanically or electrically.

According to a preferred embodiment, the partialization element 415, 435is supported and at least partially housed in the connection element 45,45′, 45″.

In the preferred embodiment in which the main axis X-X extends inseveral directions, identifying different linear sections, theconnection element 45 is suitable to connect said different linearsections. Preferably, according to the above description, each tubularfilter with the respective partialization devices is positioned along arespective linear section. Preferably, each tubular filter with therespective partialization devices is positioned inside a respectivesuction manifold tubular section 20.

According to a preferred embodiment, the support means 4 furthercomprise annular support members 48 suitable to support the respectivetubular filters to the suction manifold 2 operating at the respectiveend portions of said tubular filters.

The present invention also relates to an air suction system of a vehicleengine comprising a suction system duct fluidically connected to thevehicle engine and an air filtration device 1 in turn object of thepresent invention, according to the above description.

In addition, the present invention also relates to a suction method ofair filtered by an air suction system of a vehicle engine using an airfiltration device according to the description. Said suction methodcomprises the step of:

aspirating the air from the external environment by suction andfiltering it in parallel through each tubular air filter arranged alongthe main axis X-X.

Innovatively, the air filtration device, the air suction system andsuction method of filtered air according to the present invention amplyfulfil the aforementioned purpose overcoming the drawbacks typical ofthe prior art.

Advantageously, the air filtration device has a high filtering surfacethanks to the arrangement in series of the tubular filters, efficientlyexploited for the filtration of the air thanks to the presence of thefiltration devices which perform suction in parallel.

Advantageously, the filtering of the air exclusively in the proximalportions at the outlet mouth of the suction manifold is avoided.Advantageously, the accelerated wear of such portions is avoided.

Advantageously, the exploitation of the space in the engine compartmentis optimized. In fact, advantageously, the need to provide for suctionand filtration box-shaped bodies specifically designed to housefiltering elements is obviated. Advantageously, the filtration device isinsertable in longitudinal spaces or spaces having longitudinal sectionspresent in the engine compartment. Advantageously, the exploitation ofspace in the engine compartment is particularly optimized, particularlyin the case of hybrid powered vehicles.

Advantageously, the tubular filter does not require a further supportelement.

Moreover, advantageously the tubular filter is insertable (and lockable)or extractable (and unlockable) by means of simple and intuitiveoperations.

Moreover, advantageously, the air filtration device also solves theproblem related to the acoustic pollution of the engine. In fact, theaxial arrangement along a main axis with different linear sectionsand/or the presence of support means which comprise a partializationdevice prevent the return of engine noise towards the environmentthrough the suction system, interrupting the sound waves emitted by theengine through the suction system.

Advantageously, the air filtration device makes it possible to minimizethe acoustic emissions of the engine and its overall dimensions thanksto the installation of the filtration device in a suction ductcomprising portions made of sound-absorbent material.

In addition, innovatively, the aforementioned advantages can be seen andachieved using the suction method of filtered air described above.

It is clear that a person skilled in the art may make modifications tothe air filtration device and the air suction system described above soas to satisfy contingent requirements, all contained within the scope ofprotection as defined by the following claims.

LIST OF REFERENCE NUMBERS

-   1 air filtration device-   2 suction manifold-   21 outlet mouth-   22 inlet mouth-   20 air filtration chamber-   200 manifold tubular sections-   3 tubular filters-   31 first tubular filter-   310 first inner cavity-   311 first inner wall-   32 second tubular filter-   320 second inner cavity-   321 second inner wall-   33 intermediate tubular filter-   330 intermediate inner cavity-   331 intermediate inner wall-   4 support means-   41 partialization device-   410 suction channel-   411 partialization wall-   411′ inlet portion-   411″ outlet portion-   415 partialization element-   416 outlet passage-   42 second partialization device-   420 second suction channel-   421 second partialization wall-   421′ second inlet portion-   421″ second outlet portion-   43 intermediate partialization device-   430 intermediate suction channel-   431 intermediate partialization wall-   431′ intermediate inlet portion-   431″ intermediate outlet portion-   435 intermediate partialization element-   436 intermediate outlet passage-   45 connection element-   45′ first connection element-   45″ second connection element-   452, 452′, 452″ manifold connection wall-   X-X main axis

1. An air filtration device of an air suction system of a vehicleengine, comprising: a suction manifold extending in length along a mainaxis between a first end comprising an outlet mouth fluidicallyconnected to the air suction system, and a second end, comprising aninlet mouth; at least two tubular filters housed inside said suctionmanifold, arranged along the main axis, comprising a first tubularfilter positioned proximally to the first end, and to the outlet mouth,and a second tubular filter positioned proximal to the second end,wherein each tubular filter is traversable by air from outside to insidefiltering the air by operating in parallel, respectively comprisingcentrally a first inner cavity defined by a first inner wall of thefirst tubular filter and a second inner cavity defined by a second innerwall of the second tubular filter; a support supporting the tubularfilters in the suction manifold comprising: i) at least one connectionelement for the connection in series of two consecutive tubular filters;ii) a partialization device housed in the first inner cavity to createan obstacle to flow of air flowing inside said first inner cavity insuch a way as to promote the flow of air through the second tubularfilter and thus through the second inner cavity.
 2. Air filtrationdevice according to claim 1, wherein the support comprises a secondpartialization device housed in the second inner cavity of the secondtubular filter, wherein the second partialization device creates anobstacle to the flow of air flowing inside said second inner cavityinferior to the obstacle which the first partialization device createsin the first inner cavity.
 3. Air filtration device according to claim1, comprising at least one intermediate tubular filter positioned alongthe main axis between the first tubular filter and the second tubularfilter, which is crossable by the air from the outside to the inside,centrally comprising an intermediate inner cavity defined by anintermediate inner wall, wherein the support comprises: a firstconnection element connecting the intermediate tubular filter to thefirst tubular filter; a second connection element connecting theintermediate tubular filter to the second tubular filter.
 4. Airfiltration device according to claim 3, wherein the support comprises anintermediate partialization device housed in the intermediate innercavity to create an obstacle to the flow of air flowing inside saidintermediate inner cavity in such a way as to promote the flow of airthrough the second tubular filter and thus through the second innercavity.
 5. Air filtration device according to claim 1, wherein thepartialization device comprises a partialization wall that extends inlength occupying the respective central cavity comprising an inletportion engaging the respective inner wall or the connection element andan outlet portion distal from the respective inner wall, defining asuction channel in which the clean air aspirated through the respectivetubular filter flows.
 6. Air filtration device according to claim 5,wherein the partialization device comprises centrally an outlet passage,separated from the suction channel by the partialization wall, whereinthe air filtered by the adjacent tubular filter flows towards the outletthrough the outlet passage.
 7. Air filtration device according to claim1, wherein the partialization device comprises a partialization elementpositioned in the inner cavity in a position proximal to the outlet ofthe respective inner cavity, wherein said partialization element has asubstantially planar extension in a direction orthogonal to the mainaxis, presenting calibrated air passages.
 8. Air filtration deviceaccording to claim 7, wherein the partialization element is housed inthe suction channel in its an outlet portion, having a substantiallyannular shape.
 9. Air filtration device according to claim 7, whereinthe partialization element comprises a porous body, made of fibrousmaterial, or comprises a perforated planar body.
 10. Air filtrationdevice according to claim 7, wherein the partialization element issupported and at least partially housed in the connection element. 11.Air filtration device according to claim 1, wherein the main axisextends along a single direction that is along a single straight line.12. Air filtration device according to claim 1, wherein the main axisextends in a plurality of directions, identifying different linearsections, wherein the connection element is configured to connect saiddifferent linear sections.
 13. Air filtration device according to claim12, wherein each tubular filter is positioned along a respective linearsection, wherein the suction manifold comprises respective manifoldsections which house the respective tubular filter.
 14. An air suctionsystem of a vehicle engine comprising a suction duct system fluidicallyconnected to the vehicle engine and an air filtration device, accordingto claim 1, fluidically connected to said system suction duct, whereinthe air from the external environment is aspirated through the airfiltration device and is cleaned of any suspended particles to then flowin said system suction duct.
 15. Suction method of filtering air of anair suction system of a vehicle engine through an air filtration deviceaccording to claim 1, comprising the step of: aspirating the air fromthe external environment by suction and filtering the air in parallelthrough each tubular air filter arranged along the main axis.